U.S. patent application number 16/518340 was filed with the patent office on 2021-01-28 for tinted metal plated parts and methods of manufacturing tinted metal parts.
This patent application is currently assigned to Ford Global Technologies, LLC. The applicant listed for this patent is Ford Global Technologies, LLC. Invention is credited to Paul Kenneth Dellock, Richard Gall, David Brian Glickman, Joseph Myszka, Stuart C. Salter.
Application Number | 20210025052 16/518340 |
Document ID | / |
Family ID | 1000004218552 |
Filed Date | 2021-01-28 |
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United States Patent
Application |
20210025052 |
Kind Code |
A1 |
Dellock; Paul Kenneth ; et
al. |
January 28, 2021 |
TINTED METAL PLATED PARTS AND METHODS OF MANUFACTURING TINTED METAL
PARTS
Abstract
A method of manufacturing a tinted metal plated substrate
includes injection molding a tinted polymer layer onto an activated
metal layer of a metal plated substrate. The tinted polymer layer
is a tinted polyurethane layer or a tinted polyurea layer and the
activated metal layer can be a plasma activated metal layer, for
example, an oxygen plasma activated metal layer that is free of a
coupling agent when the tinted polymer layer is injected molded
thereon. At least one additional metallic layer can be disposed
between the activated metal layer and a polymer substrate. For
example, at least one of a nickel layer and a copper layer can be
disposed between an activated chromium layer and a polymer
substrate.
Inventors: |
Dellock; Paul Kenneth;
(Northville, MI) ; Gall; Richard; (Ann Arbor,
MI) ; Salter; Stuart C.; (White Lake, MI) ;
Glickman; David Brian; (Southfield, MI) ; Myszka;
Joseph; (Livonia, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ford Global Technologies, LLC |
Dearborn |
MI |
US |
|
|
Assignee: |
Ford Global Technologies,
LLC
Dearborn
MI
|
Family ID: |
1000004218552 |
Appl. No.: |
16/518340 |
Filed: |
July 22, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2255/06 20130101;
C23C 16/50 20130101; B32B 27/40 20130101; B05D 5/068 20130101; C23C
16/06 20130101; B32B 15/095 20130101; B05D 2202/00 20130101; B32B
2255/20 20130101; B32B 2255/26 20130101; B32B 2307/402 20130101;
C23C 28/322 20130101 |
International
Class: |
C23C 16/06 20060101
C23C016/06; C23C 28/00 20060101 C23C028/00; C23C 16/50 20060101
C23C016/50 |
Claims
1. A method of manufacturing a tinted metal plated substrate
comprising injection molding a tinted polymer layer onto an
activated metal layer of a metal plated substrate.
2. The method according to claim 1, wherein the polymer layer is a
tinted polyurethane layer or a tinted polyurea layer.
3. The method according to claim 1, wherein the activated metal
layer is a plasma activated chromium layer.
4. The method according to claim 1, wherein the activated metal
layer is an oxygen plasma activated chromium layer.
5. The method according to claim 1, wherein the activated metal
layer is free of a coupling agent when the polymer layer is
injected molded thereon.
6. The method according to claim 1, wherein the metal plated
substrate is a chrome plated metallic substrate.
7. The method according to claim 1, wherein the metal plated
substrate is a chrome plated polymer substrate.
8. The method according to claim 7, wherein the metal plated
polymer substrate is a chrome plated thermoplastic polymer
substrate.
9. The method according to claim 7, wherein the metal plated
polymer substrate is a chrome plated acrylonitrile butadiene
styrene substrate.
10. The method according to claim 7, wherein the metal plated
polymer substrate is a chrome plated polycarbonate+acrylonitrile
butadiene styrene substrate.
11. The method according to claim 7, wherein the metal plated
polymer substrate is a chrome plated nylon substrate.
12. The method according to claim 1, wherein the metal plated
substrate comprises a chrome plated substrate with an activated
chromium layer and at least one additional metallic layer between
the activated chromium layer and a polymer substrate.
13. The method according to claim 12, wherein the at least one
metallic layer comprises a nickel layer and a copper layer.
14. The method according to claim 1 further comprising injection
molding a polymer substrate, forming a chromium layer across at
least a portion of the polymer substrate and plasma activating the
chromium layer to form a chrome plated substrate with an activated
chromium layer.
15. The method according to claim 14 further comprising forming a
nickel layer onto the injection molded polymer substrate and
forming a copper layer onto the nickel layer before forming the
chromium layer.
16. The method according to claim 15, wherein the tinted polymer
layer is injected molded onto the activated chromium layer of the
metal plated substrate using the same injection molding machine
used to injection mold the polymer substrate.
17. A method of manufacturing a tinted chrome plated substrate
comprising: injection molding a substrate; forming a chromium layer
across at least a portion of the substrate; activating the chromium
layer; and injection molding a tinted polymer layer onto the
activated chromium layer.
18. The method according to claim 17, wherein the substrate is a
polymer substrate, the chromium layer is plasma activated and the
plasma activated chromium layer is free of a coupling agent when
the tinted polymer layer is injected molded onto the plasma
activated chromium layer.
19. The method according to claim 17, wherein the substrate is a
polymer substrate, the chromium layer is plasma activated and the
tinted polymer layer is a tinted polyurethane layer or a tinted
polyurea layer.
20. A method of manufacturing a tinted chrome plated substrate
comprising: injection molding a polymer substrate; forming a copper
layer onto the polymer substrate; forming a nickel layer onto the
copper layer; forming a chromium layer onto the copper layer;
plasma activating the chromium layer; and injection molding a
tinted polymer layer onto the activated chromium layer.
Description
FIELD
[0001] The present disclosure relates to metal plated parts and
particularly to tinted metal plated parts.
BACKGROUND
[0002] The statements in this section merely provide background
information related to the present disclosure and may not
constitute prior art.
[0003] Components with an outer chromium containing layer provide a
shiny, and sometimes mirror, surface that is aesthetically pleasing
to consumers. Such components include chrome plated exterior and
interior trim parts for a vehicle such as a chrome plated grille, a
chrome plated console part, among others. Tinted chrome plated
parts, i.e., chrome plated parts with a "tinted" color, are known,
but the cost to manufacture such parts can be two to three times
the cost of the chrome plated part itself.
[0004] The present disclosure addresses the issues of tinted chrome
plated parts other issues related to manufacturing tinted chrome
plated parts.
SUMMARY
[0005] This section provides a general summary of the disclosure
and is not a comprehensive disclosure of its full scope or all of
its features.
[0006] In one form of the present disclosure, a method of
manufacturing a tinted metal plated substrate includes injection
molding a tinted polymer layer onto an activated metal layer (e.g.,
an activated chromium layer) of a metal plated substrate (e.g., a
chrome plated substrate). In some aspects the tinted polymer layer
is a tinted polyurethane layer or a tinted polyurea layer and the
activated metal layer is a plasma activated metal layer. In such
aspects the activated metal layer is an oxygen plasma activated
metal layer that is free of a coupling agent when the tinted
polymer layer is injected molded thereon.
[0007] The method includes injection molding the tinted polymer
layer onto a metal plated metallic substrate, or in the
alternative, injection molding the tinted polymer layer onto a
metal plated polymer substrate. Non-limiting examples of metal
plated polymer substrates include a chromium plated thermoplastic
polymer substrate, a chromium plated acrylonitrile butadiene
styrene substrate, a chromium plated polycarbonate+acrylonitrile
butadiene styrene substrate, and a chromium plated nylon substrate,
among others.
[0008] In some aspects of the present disclosure, the metal plated
substrate includes at least one additional metallic layer between
the activated metal layer and a polymer substrate. For example, at
least one of a nickel layer and a copper layer is disposed between
an activated chromium layer and a polymer substrate.
[0009] The method can further include injection molding a polymer
substrate, forming a metal layer across at least a portion of the
polymer substrate and plasma activating the metal layer to form the
metal plated substrate with the activated metal layer. Also, a
nickel layer is formed onto the injection molded polymer substrate
and a copper layer is formed on the nickel layer before forming the
metal layer. In some aspects the tinted polymer layer is injected
molded onto the activated metal layer of the metal plated substrate
using the same injection molding machine used to injection mold the
polymer substrate.
[0010] In another form of the present disclosure, a method of
manufacturing a tinted chrome plated substrate includes injection
molding a substrate, forming a chromium layer across at least a
portion of the substrate, activating the chromium layer; and
injection molding a tinted polymer layer onto the activated
chromium layer. In some aspects of the present disclosure, the
substrate is a polymer substrate, the chromium layer is plasma
activated and the plasma activated chromium layer is free of a
coupling agent when the tinted polymer layer is injected molded
onto the plasma activated chromium layer. Also, the tinted polymer
layer can be a tinted polyurethane layer or a tinted polyurea
layer.
[0011] In still another from of the present disclosure, a method of
manufacturing a tinted chrome plated substrate includes injection
molding a polymer substrate, forming a copper layer onto the
polymer substrate, forming a nickel layer onto the copper layer,
forming a chromium layer onto the copper layer, plasma activating
the chromium layer, and injection molding a tinted polymer layer
onto the activated chromium layer.
[0012] Further areas of applicability will become apparent from the
description provided herein. It should be understood that the
description and specific examples are intended for purposes of
illustration only and are not intended to limit the scope of the
present disclosure.
DRAWINGS
[0013] In order that the disclosure may be well understood, there
will now be described various forms thereof, given by way of
example, reference being made to the accompanying drawings, in
which:
[0014] FIG. 1 is a perspective view of one form of a tinted metal
plated substrate according to the teachings of the present
disclosure;
[0015] FIG. 2 is a top view of the tinted metal plated substrate in
FIG. 1;
[0016] FIG. 3 is a perspective view of another form of a tinted
metal plated substrate according to the teachings of the present
disclosure; and
[0017] FIGS. 4A-4E illustrate a plurality of steps for
manufacturing a tinted metal plated substrate according to the
teachings of the present disclosure with: FIG. 4A illustrating one
step for manufacturing a tinted metal plated substrate; FIG. 4B
illustrating another step for manufacturing the tinted metal plated
substrate; FIG. 4C illustrating still another step for
manufacturing the tinted metal plated substrate; FIG. 4D
illustrating yet another step for manufacturing the tinted metal
plated substrate; and FIG. 4E illustrating still yet another step
for manufacturing the tinted metal plated substrate.
[0018] The drawings described herein are for illustration purposes
only and are not intended to limit the scope of the present
disclosure in any way.
DETAILED DESCRIPTION
[0019] The following description is merely exemplary in nature and
is not intended to limit the present disclosure, application, or
uses. It should be understood that throughout the drawings,
corresponding reference numerals indicate like or corresponding
parts and features. Examples are provided to fully convey the scope
of the disclosure to those who are skilled in the art. Numerous
specific details are set forth such as types of specific
components, devices, and methods, to provide a thorough
understanding of variations of the present disclosure. It will be
apparent to those skilled in the art that specific details need not
be employed and that the examples provided herein, may include
alternative embodiments and are not intended to limit the scope of
the disclosure. In some examples, well-known processes, well-known
device structures, and well-known technologies are not described in
detail.
[0020] Referring now to FIG. 1, a metal plated substrate 10 (also
referred to herein as a "metal plated part") according to one form
of the present disclosure includes a substrate 100, a metallic
layer 130 (also referred to herein simply as a "metal layer")
disposed on the substrate 100 and an injection molded tinted layer
140 disposed on the metal layer 130. The substrate 100 includes an
outer surface 102 (+z direction), and the metal layer 130 includes
an inner surface 132 (-z direction) and an outer surface 134 (+z
direction). In some aspects of the present disclosure the inner
surface 132 of the metal layer 130 is disposed in contact with the
outer surface 102 of the substrate 100 and the injection molded
tinted layer 140 is disposed in contact with the outer surface 134
of the metal layer 130. In such aspects the outer surface 134 is
free from a coupling agent, i.e., the injection molded tinted layer
140 is disposed in contact with the outer surface 134 without the
use of a coupling agent such as silane coupling agents, chromium
complexes, inorganic esters, zirconates, aluminates, and titanates,
among others.
[0021] The substrate 100 can be any known or yet to be developed
substrate including, but not limited to, a substrate for a metal
plated vehicle grille, a substrate for a metal plated vehicle
console part, a substrate for a metal plated appliance part, among
others. Also, the substrate 100 can be formed from known or yet to
be developed polymer materials, metallic materials, ceramic
materials, and combinations thereof. Non-limiting examples of
substrate materials include thermoplastic polymers such as
acrylonitrile butadiene styrene (ABS), polycarbonate+acrylonitrile
butadiene styrene (PC/ABS), nylon, among others.
[0022] The outer surface 134 of the metal layer 130 can be smooth,
i.e., does not have intentional indentations, roughness, logos,
patterns, grain, and the like, and may have a mirror surface finish
as depicted by region 135 in FIG. 2. In the alternative, or in
addition to, the outer surface 134 has at least one intentional
indentation, roughness, logo 136, pattern 138, grain, among others
as shown in FIG. 2. The metal layer 130 can be any metal or
combination of metals (i.e., an alloy) formed or deposited onto the
substrate 100 using known or yet to be developed metal layer
deposition techniques. Non-limiting examples of metals include
chromium, nickel, copper, iron, tin, silver, gold and alloys
thereof. Non-limiting examples of metal layer forming or deposition
techniques include electrochemical deposition, electroless
deposition, physical vapor deposition (PVD), chemical vapor
deposition (CVD), among others.
[0023] The injection molded layer 140 can be formed from known or
yet to be developed polymeric materials. Non-limiting examples of
polymers used to form the injection molded tinted layer 140 include
polyurethane (e.g., thermoplastic polyurethane) and polyurea, among
others. The injection molded tinted layer 140 can be a dear coat
layer, for example, a tinted clear coat layer that is transparent
such that the outer surface 134 of the metal layer 130 is visible
through the injection molded tinted layer 140 to an observer
viewing the tinted metal plated part 10. It should be understood
that a tinted injection molded tinted layer 140 provides a "color"
(e.g., pink, blue, red, among others) and an aesthetically pleasing
appearance or visual effect to a metal plated part 10 being viewed
by an individual while still allowing the underlying metal layer
130, with or without a logo 126, pattern 138, and the like, to be
seen by the individual. It should also be understood that a
non-tinted clear coat layer (i.e., an injection molded layer 140
without color) can be injection molded onto the metal layer 130 to
provide a chromium (silvery metallic) appearance, and such a metal
plated part is included within the teachings of the present
disclosure.
[0024] Referring now to FIG. 3, a metal plated substrate 12
according to another form of the present disclosure includes the
substrate 100, the metal layer 130 and the injection molded tinted
layer 140. However at least one additional layer is disposed
between the outer surface 102 of the substrate 100 and the inner
surface 132 of the metal layer 130. In some aspects a copper
containing layer 110 (also referred to herein simply as a "copper
layer") is disposed between the substrate 100 and the metal layer
130. In other aspects a nickel containing layer 120 (also referred
to herein simply as a "nickel layer") is disposed between the
substrate 100 and the metal layer 130. In still other aspects a
copper layer 110 is disposed between the substrate 100 and the
metal layer 130, and a nickel layer 120 is disposed between the
copper layer 110 and the metal layer 130. Similar to the metal
plated substrate 10 shown in FIG. 1 in some aspects the injection
molded layer 140 is disposed in contact with the outer surface 134
of the metal layer 130. In such aspects the outer surface 134 is
free from a coupling agent, i.e., the injection molded layer 140 is
disposed in contact with the outer surface 134 without the use of a
coupling agent.
[0025] Referring now to FIGS. 4A-4E, FIG. 4A illustrates forming
the substrate 100 in an injection molding machine 200. The
injection molding machine 200 includes a mold 205 with a first die
210 and a second die 220. A substrate material is injected into a
cavity or space (not labeled) between the first die 210 and the
second die 220 to form the substrate 100. After the substrate 100
is formed, it is removed from the mold 205 and a precursor metal
layer 130' is formed on at least one surface 102 of the substrate
100 as shown in FIG. 4B. As used herein, the phrase "precursor
metal layer" refers to a metal layer prior to being activated as
described herein. As noted above, one or more layers, for example a
copper layer 110 and/or a nickel layer 120, can be disposed between
the substrate 100 and the precursor metal layer 130'.
[0026] Referring now to FIG. 4C, the precursor metal layer 130',
i.e., the outer surface 134 of the precursor metal layer 130', is
activated to provide the metal layer 130 (also referred to herein
as an "activated metal layer") on the substrate 100. In some
aspects the precursor metal layer 130' is activated by a plasma
treatment. For example, at least the precursor metal layer 130' is
positioned within a plasma chamber, a process gas (e.g., a gas with
oxygen, nitrogen and/or air) is introduced into the plasma chamber,
and electrical energy is applied such that a plasma is formed
within the plasma chamber. It should be understood that the plasma
in the plasma chamber (i.e., the plasma treatment) reduces, removes
and/or eliminates contaminants such as oils, grease, among others
from an outer surface of the metal layer 130. That is, the plasma
treatment provides a pristine surface suitable for bonding without
producing harmful waste material. Also, oxygen atoms within the
plasma bond with the outer surface of the precursor metal layer
130' and creates active surface sites that enhance bonding of the
outer surface 134 of the metal layer 130 with the injected molded
layer 140. It should be understood that the combination of the
plasma treatment of the precursor metal layer 130' and the
injection molding of the tinted layer onto the metal layer 130
reduces or removes the need for a coupling agent to produce the
metal plated substrate 10 or 12. It should also be understood that
other surface treatments such as flame treatment, among others, can
be sued to activate the precursor metal layer 130'.
[0027] Referring now to FIG. 4D, in one form of the present
disclosure the substrate 100 with the metal layer 130 is positioned
or placed back into another injection molding machine 300 with a
mold 305 comprising a first mold 310 and a second mold 320. A small
gap or space 330 is provided between the outer surface 134 of the
metal layer 130 and a surface 322 of the second die 320. In another
from of the present disclosure, the substrate 100 with the metal
layer 130 is placed back into in the mold 205 of the injection
molding machine 200 (FIG. 4A) and the first die 210 and the second
die 220 positioned such that the space 230 (e.g., 0.5 mm) is
present between the activated metal layer 130 and a surface (not
labeled) of the second die 220. In either form, tinted polyurethane
or tinted polyurea, among others, is injected molded into the space
330 to form the injection molded tinted layer 140 on the metal
layer 130 as shown in FIG. 4E, thereby providing a tinted metal
plated substrate 10 (FIG. 1). It should be understood, and as noted
above, the activated metal layer 130 enhances bonding with the
injection molded tinted layer 140 such that a resilient,
self-healing surface that is resistant to chipping when impact by
stones or rocks is provided.
[0028] It should be understood from the teachings of the present
disclosure that a metal plated part with an injection molded tinted
layer and a method for manufacturing the metal plated part with the
injection molded tinted layer is provided. The metal plated part
combines the appearance of an underlying metal layer with a tinted
(transparent) outer to provide a pleasing and possibly unique
visual appearance to consumers and enhance consumer satisfaction
with machines (e.g., vehicles and appliances), artwork, furniture,
tools, among others, with the metal plated part.
[0029] Although the terms first, second, third, etc. may be used to
describe various elements, components, regions, layers and/or
sections, these elements, components, regions, layers and/or
sections, should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer
and/or section, from another element, component, region, layer
and/or section. Terms such as "first," "second," and other
numerical terms when used herein do not imply a sequence or order
unless clearly indicated by the context. Thus, a first element,
component, region, layer or section, could be termed a second
element, component, region, layer or section without departing from
the teachings of the example forms. Furthermore, an element,
component, region, layer or section may be termed a "second"
element, component, region, layer or section, without the need for
an element, component, region, layer or section termed a "first"
element, component, region, layer or section.
[0030] Specially relative terms, such as "inner," "outer,"
"beneath," "below," "lower," "above," "upper," and the like, may be
used herein for ease of description to describe one element or
feature's relationship to another element(s) or feature(s) as
illustrated in the figures. Spatially relative terms may be
intended to encompass different orientations of the device in use
or operation in addition to the orientation depicted in the
figures. For example, if the device in the figures is turned over,
elements described as "below" or "beneath" other elements or
features would then be oriented "above" the other elements or
features. Thus, the example term "below" can encompass both an
orientation of above or below. The device may be otherwise oriented
(rotated 90 degrees or at other orientations) and the spatially
relative descriptors used herein interpreted accordingly.
[0031] As used herein, the phrase at least one of A, B, and C
should be construed to mean a logical (A OR B OR C), using a
non-exclusive logical OR, and should not be construed to mean "at
least one of A, at least one of B, and at least one of C.
[0032] Unless otherwise expressly indicated, all numerical values
indicating mechanical/thermal properties, compositional
percentages, dimensions and/or tolerances, or other characteristics
are to be understood as modified by the word "about" or
"approximately" in describing the scope of the present disclosure.
This modification is desired for various reasons including
industrial practice, manufacturing technology, and testing
capability.
[0033] The terminology used herein is for the purpose of describing
particular example forms only and is not intended to be limiting.
The singular forms "a," "an," and "the" may be intended to include
the plural forms as well, unless the context clearly indicates
otherwise. The terms "including," and "having," are inclusive and
therefore specify the presence of stated features, integers, steps,
operations, elements, and/or components, but do not preclude the
presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. The
method steps, processes, and operations described herein are not to
be construed as necessarily requiring their performance in the
particular order discussed or illustrated, unless specifically
identified as an order of performance. It is also to be understood
that additional or alternative steps may be employed.
[0034] The description of the disclosure is merely exemplary in
nature and, thus, examples that do not depart from the substance of
the disclosure are intended to be within the scope of the
disclosure. Such examples are not to be regarded as a departure
from the spirit and scope of the disclosure. The broad teachings of
the disclosure can be implemented in a variety of forms. Therefore,
while this disclosure includes particular examples, the true scope
of the disclosure should not be so limited since other
modifications will become apparent upon a study of the drawings,
the specification, and the following claims.
* * * * *